Cutting apparatus for window coverings and methods therefor

ABSTRACT

An apparatus for cutting a window covering including a head rail, a bottom rail and slats includes a base having a substantially flat cutting surface, and a frame overlying the cutting surface. The base includes a clamping assembly for securing the window covering atop the cutting surface with the bottom rail, slats and top rail in a side-by-side arrangement over the cutting surface. The apparatus includes a cutting assembly having a cutting blade with a cutting edge for sliding along a movement axis having a first component of movement extending in a direction substantially parallel to the cutting surface and a second component of movement extending in a direction substantially perpendicular to the cutting surface. A driver is connected with the cutting assembly for moving the cutting blade toward the cutting surface, wherein the cutting edge simultaneously cuts through the bottom rail, the slats and the head rail.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is a divisional application of application Ser.No. 09/054,845, filed Apr. 3, 1998, now U.S. Pat. No. 6,435,066, whichclaims benefit of U.S. Provisional Application Ser. No. 60/068,039 filedDec. 18, 1997, and the disclosures of both of these applications arehereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to the art of window coveringsand more specifically relates to cutting machines and methods forcutting window coverings to specified lengths.

BACKGROUND OF THE INVENTION

Retail outlets frequently sell many different types of window coveringssuch as draperies, curtains, venetian blinds and shades. These windowcoverings generally extend horizontally across a window opening and aretypically sized to accommodate the dimensions of the window opening. Onepopular type of window covering is a window shade having a head rail, abottom rail and a window covering material between the head rail and thebottom rail. Common window covering materials include slats, such as PVCslats, or fabric. One problem with such window shades is that the widthof the head rail, the bottom rail and the window covering material mustbe customized to match the exact dimensions of the window opening. Inresponse to this problem, a number of options have been developed sothat consumers may obtain customized window shades which are sized tofit a specific window opening.

In accordance with a first option, a customer typically visits aspecialty shop or department store and places an order for customizedwindow shades. This option requires the customer to first measure thewindow opening and submit the measurements to a salesperson. Thesalesperson will then submit the order to a factory or distributioncenter where the window shade is cut to the specified length. Thisoption is rather time consuming, because the customer must make at leasttwo visits to the retail outlet in order to obtain the customizedproduct, i.e. a first visit to place the order and a second visit topick up the product. In addition, this particular option is relativelyexpensive.

A second option involves selecting the window shade from a stock ofpre-sized shades maintained at the retail establishment. Typically, onlycertain standard sizes are carried because some window openings,especially in newer homes and offices, are of standard dimensions. Thesepre-stocked, standardized window shades are usually much less expensivethan those obtained from custom specialty shops because stocked shadesmay be mass-produced in an economical manner. In addition, the cost tothe consumer is reduced because there is no need to perform a cutting orsizing operation at the retail establishment.

A third option has recently evolved. This particular option involves thein-store sizing or cutting of the window shades to match the exactwindow dimensions specified by the customer. Various machines andmethods for performing these tasks are disclosed in U.S. Pat. Nos.5,339,716; 5,037,253; 5,456,149; 4,993,131; 5,072,494 and 5,103,702.These various disclosures have been generally inadequate at providingsystems for efficiently and accurately sizing window shades to specifiedlengths. For example, most of the systems disclosed are too complex tobe operated by a typical retail salesperson having an average degree oftraining. In addition, many of these systems require numerous steps inorder to cut the window shade, i.e. the head rail is cut in a firstcutting operation and the window covering material is cut in a secondcutting operation. Further, these systems, and particularly the cuttingblades of these systems exert a tremendous amount of force upon thewindow shade being cut which often results in the cut ends of the shadesbeing uneven, chipped or cracked. These defects produce a final productof inferior quality.

Thus, there is a need for a cutting apparatus for window shades capableof efficiently customizing window shades to fit window dimensionsspecified by customers. There is also a need for a cutting apparatus forcutting a window shade to a specified length, whereby the entire windowshade, namely the head rail, the bottom rail and the window coveringmaterial are all cut simultaneously in a single cutting stroke, therebysaving time and reducing operator errors. Moreover, the cuttingapparatus should produce a final product having a high-quality,professionally-cut appearance. Applicant is presently the exclusivelicensee of such an improved cutting machine which is disclosed in U.S.patent application Ser. No. 08/627,015 entitled “End Trimming Device ForBlinds”, the disclosure of which is hereby incorporated by referenceherein. Another improved cutting device is sold by the Applicant,Springs Window Fashions, under the trademark “Crystal Pleat Cut-DownMachine.”

However, still further improvements would be desirable.

SUMMARY OF THE INVENTION

In accordance with certain preferred embodiments of the presentinvention, a cutting apparatus is provided for cutting a window shade toa specified length. The window shade preferably includes a head rail, abottom rail and a window covering material or covering material. Thewindow covering material or covering material typically includes afabric or slats provided between the head rail and the bottom rail. Thehead rail and the bottom rail preferably comprise a substantially ruggedmaterial, such as extruded plastic, which can be readily cut tospecified lengths.

The cutting apparatus preferably includes a base having a top or cuttingsurface and a frame overlying the cutting surface of the base. The frameis preferably mounted to the base to form a rigid structure. The frameand the cutting surface define a receiving area therebetween forreceiving one or more window shades which will be cut in the cuttingapparatus. A cutting assembly is slidably mounted to the frame forsliding along a movement axis toward and away from the receiving area.The frame preferably includes one or more guide tracks which are angledwith respect to the cutting surface of the base and the cutting assemblyis slidably mounted in the guide tracks so that the movement axis isdiagonal to the cutting surface of the base. The cutting assemblyincludes a cutting blade having a cutting edge facing the receivingarea. The cutting apparatus also includes a mechanical element, such asa driver, which may be operated to impart sliding motion to the cuttingassembly. The driver may include a rack and pinion gear arrangement, aratcheting mechanism, a screw-activated element, a pneumatic element oran electrical-motor operated device. In one particular preferredembodiment the cutting assembly includes a rack having a plurality ofteeth. A pinion, having a plurality of teeth at a periphery thereof, isrotatably mounted in the frame. The pinion is matingly engaged with therack so that when the pinion is rotated, the pinion imparts slidingmotion to the cutting assembly to move the cutting blade diagonallythrough the receiving area for cutting the window shade to the specifiedlength. As the cutting blade moves toward and away from the cuttingsurface, the cutting edge remains at all times substantially parallel tothe top of the cutting surface.

The base may include a support guide, provided over the cutting surfacethereof, for guiding movement of the window shade across the cuttingsurface of the base and towards the receiving area. In preferredembodiments, the support guide includes a mandrel which engages at leastone of the head rails or bottom rails and which most preferably engagesthe head rail during cutting operations. The mandrel extends along thecutting surface of the base from a first end of the cutting surface to asecond end of the cutting surface. The second end of the cutting surfaceis preferably adjacent the cutting blade.

In certain preferred embodiments the base includes a clamp assembly forsecuring the window shade over the cutting surface of the base. Theclamp preferably includes a clamp block having a threaded bore, athreaded shaft which is capable of being rotated and a crank handle. Thethreaded shaft has a first end which is threadably connected to theclamp block and a second end which is rotatably connected to the crankhandle. Rotation of the crank handle moves the clamp block into and outof engagement with the window shade. The crank handle is preferablyrotated in a clockwise or counter-clockwise direction so as to apply aclamping force to the window shade. In other preferred embodiments theclamp may include a pneumatic device, an electrically operated device, ascrew device, a ratcheting device or a weight.

The cutting blade is preferably provided at the second end of thecutting surface and has a longitudinal axis which is substantiallyperpendicular to the longitudinal axis of the guide rail. The cuttingblade has a first face which is substantially flat and a second facewhich includes a pocketed portion. The pocketed portion of the cuttingblade is preferably the only section of the blade which engages and cutsthe window shade. The pocket is substantially thinner than the area ofthe cutting blade which surrounds the pocket. The pocketed portionincludes a tapered region which is contiguous with the cutting edge andwhich extends up and away from the cutting edge. The tapered region hasa first tapered section or bevel which extends from the cutting edge.The first tapered section and the substantially flat first face define afirst acute angle. The tapered region includes a second tapered sectionwhich extends from the first tapered section. The second tapered sectionand the substantially flat first face define a second acute angle whichis smaller than the first acute angle. The substantially flat first faceof the cutting blade preferably faces upstream toward the first end ofthe top surface of the base while the second face (i.e. the faceincluding the pocketed portion) preferably faces downstream and awayfrom the first end of the top surface.

The cutting blade preferably includes any material, man-made ornaturally occurring, having the strength and/or durability toefficiently cut through the shade assembly, and more preferably includescarbide steel or diamond.

The cutting apparatus also preferably includes a measuring assemblyadjacent and/or downstream from the cutting blade for measuring thewindow shade. Specifically, the measuring assembly provides a measuringtool for defining the exact length of the end portion of the windowshade to be cut. The measuring assembly preferably includes a stop blockwhich abuts against the end portion of the window shade. The stop blockis connected to a cam follower which in turn is connected to the pinionso that the stop block moves away from the end of the window shade asthe cutting blade slices through the window shade. By camping away, thestop block allows the cut end portion of the window shade to pivot awayfrom the cutting blade which minimizes the forces exerted by the cuttingblade upon the window shade. Thus, the stop block is movable between afirst position and a second position. In the first position, the stopblock abuts against the end portion of the window shade. In the secondposition the stop block is not in contact with the end portion of thewindow shade because the stop block cams away from the end portion.

Another aspect of the present invention provides a method of cutting awindow shade to a specified length. In certain preferred embodiments amethod of cutting the window shade includes providing a cuttingapparatus having a receiving area for receiving the window shade wherebythe cutting apparatus includes a cutting blade slidably mounted thereinfor sliding along a movement axis toward and away from the receivingarea. Next, the window shade is provided in the receiving area and thecutting blade is passed diagonally through the receiving area and thewindow shade for cutting off an end portion of the window shade toprovide a window shade having a specified length. Initially, the windowshade is inserted into the first end of the cutting apparatus and slidalong a cutting surface of the base toward the cutting blade so that thecutting blade overlies the end portion of the window shade which is tobe cut. The measuring assembly is then utilized to determine the exactlength of the end portion of the window shade being cut. Once the exactlength of the end portion to be cut has been determined, the crankhandle of the clamping assembly is rotated so that the clamping blockmoves into engagement with the window shade so as to secure the windowshade between the clamp block and the guide rail. The crank continues tobe rotated until the clamping block has secured the window shade overthe cutting surface of the base. The pinion is then rotated to move thecutting assembly. A lever handle is preferably connected to the pinionto facilitate rotation of the pinion. Rotation of the pinion slides thecutting assembly in the angled guide tracks along the movement axiswhich is diagonal to the cutting surface of the base so that the cuttingblade slices diagonally through the window shade. As the cutting bladeslices through the window shade, the stop block cams away from the endportion of the window shade being cut so that the cut end portion isfree to pivot away from the cutting blade. Because the end of the windowshade being cut is free to pivot away from the blade, the compressionforces exerted by the cutting blade upon the window shade are greatlyreduced which greatly reduces the likelihood that the head rail or thebottom rail will crack while being cut. After the window shade has beencompletely cut, the direction of the lever handle is preferably reversedto return the cutting blade to its initial position. The measuringassembly moves back towards the cutting blade as the handle is returnedto its initial start position. At this point the window shade may beremoved from the cutting apparatus. In certain instances it may bepreferable to trim or cut a second end of the window shade to aspecified length. This may be accomplished by inserting the second endof the window shade into the cutting apparatus and repeating the stepsdescribed above.

These and other objects, features and advantages of the presentinvention will be more readily apparent from the detailed description ofthe preferred embodiment set forth below and when taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded perspective view of a cutting apparatus forcutting a window shade to a desired length according to one preferredembodiment of the present invention.

FIG. 2A shows a front view of the cutting apparatus shown in FIG. 1.

FIG. 2B shows a right side view of the cutting apparatus shown in FIG.2A.

FIG. 3A shows a perspective front view of one preferred window shade cutto a specified length in the cutting apparatus shown in FIG. 1.

FIG. 3B shows a side view of the window shade shown in FIG. 3A.

FIG. 4A shows a top view of a base of the cutting apparatus shown inFIG. 1 according to one preferred embodiment of the present invention.

FIG. 4B shows a right side view of the base shown in FIG. 4A along thesectional line designated 4B—4B in FIG. 4A.

FIG. 5A shows a fragmentary view of a face of a cutting blade of thecutting apparatus shown in FIG. 1 according to certain preferredembodiments of the present invention.

FIG. 5B shows a fragmentary side view of the cutting blade shown in FIG.5A along the sectional line designated 5B—5B in FIG. 5A.

FIG. 5C shows a cross-sectional fragmentary side view of the cuttingblade shown in FIG. 5A along the sectional line designated 5C—5C in FIG.5A.

FIG. 5D shows a cross-sectional fragmentary side view of a pocketportion of the cutting blade shown in FIG. 5A.

FIG. 6A shows a fragmentary top view of the window shade shown in FIG.3A after the window shade has been inserted into the cutting apparatusof FIG. 1.

FIG. 6B shows a cross-sectional end view of the window shade and cuttingapparatus shown in FIG. 6A.

FIG. 7A shows a simplified view of FIG. 6B with the cutting bladeinitially contacting the window shade in accordance with certainpreferred embodiments of the present invention.

FIG. 7B shows the cutting blade of FIG. 7A during a further stage of acutting operation.

FIG. 7C shows the cutting blade of FIG. 7B during a still further stageof the cutting operation.

FIG. 8A shows a fragmentary side view of FIG. 7A.

FIG. 8B shows a fragmentary side view of FIG. 7C.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1, 2A and 2B, preferred embodiments of the presentinvention provide a cutting apparatus 20 for cutting or sizing a windowshade to a specified length. The cutting apparatus 20 preferablyincludes a base 22 having a substantially flat cutting surface 24 and aframe 26 which overlies the substantially flat cutting surface 24 of thebase 22. The frame 26 is mounted to the base 22 so that the frame 26 andthe base 22 form a substantially rigid structure. The frame 26 includesguide tracks 28A and 28B which are angled with respect to the cuttingsurface 24 of the base 22. The angle formed by the guide tracks 28A, 28Band the cutting surface 24 is preferably between one to 89 degrees. Acutting assembly 30 including a cutting blade 32 is slidably mounted inthe guide tracks 28A and 28B and moves along a movement axis designatedA—A which is diagonal to the cutting surface 24 of the base 22. Thecutting surface 24 of the base 22 and the frame 26 define an aperture orreceiving area 34 into which an end portion of a window shade ispreferably inserted in order to be cut by the cutting apparatus 20. Thecutting apparatus 20 is preferably capable of cutting entirely throughthe end of the window shade with a single pass of the cutting blade 32.The terms “top”, “bottom”, “front”, “side”, “first” and “second” areused herein to indicate directions relative to the cutting apparatusitself. It should be understood that these terms are used to refer tothe frame of reference of the apparatus itself, and not to the ordinary,gravitational frame of reference.

Referring to FIGS. 3A and 3B, one preferred window shade 36 capable ofbeing cut by the cutting apparatus 20 described above includes aheadrail 38, a bottom rail 40 and window covering material 41therebetween. The head rail 38 and the bottom rail 40 preferably includean extruded plastic material. The window covering material 41 mayinclude a fabric, such as a point bonded polyester blend material, ormay include slats which generally comprise a somewhat flexible material,such as polyvinyl chloride (PVC). The top portion of the head rail 38has a “C”-shaped opening 42 which may be used for securing the shade 36to a window opening or for rigging the window shade 36 with controllines. The head rail 38 also preferably includes a lower “C”-shapedopening 46 for securing a top section of the window covering material41. The bottom rail 40 also has a “C”-shaped opening 50 for receivingand securing a bottom section of the window covering material 41. Thewindow shade 36 also includes removable end caps 44 at the ends of thehead rail 38 and the base rail 40.

The end caps 44 stabilize the ends of the head rail 38 and the base rail40 and improve the overall aesthetic appearance of the window shade 36.The ends caps 44 are preferably removed before the window shade 36 iscut and reinstalled into the rail ends after the cutting operation.Referring to FIGS. 4A and 4B, the base 22 generally includes a hardenedsteel. The cutting surface 24 of the base 22 preferably has a first end52 which initially receives the window shade 36 and a second end 54which is adjacent the cutting blade (FIG. 2A). As shown in FIG. 2A, asafety guard 56, designated the left hand guard, preferably overlies thefirst end 52 of the cutting surface 24 so as to prevent an operator fromplacing his or her hands under the cutting blade 32. The hand guard 56preferably comprises a hardened, rugged material such as a metal or aclear plastic material, such as Lexan, Plexiglas or Acrylic. Referringto FIGS. 4A and 4B, the base 22 preferably includes a guide rail 58which overlies the cutting surface 24 and extends from the first end 52of the cutting surface 24 to the second end 54 thereof. The guide rail58 serves to align the head rail 38 over the cutting surface 24 of thebase 22 and guide the head rail 38 over the cutting surface 24. Theguide rail 58 is preferably a mandrel shaped to fit relatively snuglywithin the “C”-shaped opening 42 at the top of the headrail 38. The base22 also includes a clamping assembly for securing the window shade 36 tothe cutting surface 24 of the base 22 prior to cutting the window shade36. The clamping assembly includes a clamp block 60 extending over thecutting surface 24 in a longitudinal direction which is substantiallyparallel to the guide rail 58. The clamp block 60 preferably movesindependently of the base and is attached to a sliding portion 62provided in a slot 64 cut into the cutting surface 24 of the base 22 sothat the clamp block 60 may slide towards and away from the guide rail58. The clamp block 60 is connected to a threaded block 66 having athreaded bore therein. The threaded block 66 is preferably rigidlyconnected to the base 22 so that the threaded block does not moveindependently of the base 22. The clamping assembly also includes arotatable, threaded shaft 68 having a first end 70 which is connected tothe clamp block 60 and a second end 72 which is rotatably connected to acrank handle 74. Rotation of the crank handle 74 rotates the threadedshaft 68 which in turn moves the clamping block 60 toward and away fromthe guide rail 58.

The top surface 24 of the base 22 preferably includes a backup 76 whichopposes the cutting blades 32. The backup 76 is preferably located atthe second end 54 of the cutting surface 24 of the base 22 and extendsslightly beyond the second end 54 of the cutting surface 24. In certainpreferred embodiments the backup 76 extends between approximately 1/32inch and 3/32 inch beyond the second end 54. The backup 76 preferablyincludes a hardened material, such as a nylon material, which isrelatively softer than the material comprising the cutting blade 32, sothat the backup is stiff enough to adequately support the window shade36 and so that the cutting blade 32 is not prematurely dulled when itrepeatedly abuts against the backup 76 during cutting operations.

Referring to FIG. 2B, the frame 26 includes guide tracks 28A and 28Bwhich are angled relative to the cutting surface 24 of the base 22. Thecutting assembly 30 is slidably mounted in the guide tracks 28A and 28Band is capable of sliding within the guide tracks 28A and 28B along themovement axis designated A—A. The movement axis A—A has both a downwardvertical component (Y-axis) and a horizontal component (X-axis). Thus,the movement axis A—A is diagonal with respect to the cutting surface 24of the base 22 so that the cutting blade 32 moves along both the y axisand x axis with respect to the cutting surface 24. The cutting assembly30 preferably includes a rack 78 having a plurality of teeth 80 so thatthe cutting assembly 30 may be operated using a rack and pinionmechanism. A driver such as a pinion 82 having a plurality of teeth 84is rotatably mounted in the frame 26 and is matingly engaged with therack 78 so that the teeth 84 of the pinion 82 mesh with the teeth 80 ofthe rack 78. A lever handle 86 is connected to the pinion 82 andpreferably has considerable length for providing leverage so that thepinion 82 may be readily rotated by an operator. As the pinion 82rotates, the teeth 84 of the pinion 82 mesh with the teeth 80 of therack 78 so as to impart sliding motion to the cutting assembly 30 andmove the cutting assembly 30 within the guide tracks 28A and 28B.

Referring to FIG. 2A, a safety pin 88 is provided at an exterior surfaceof the frame 26. The safety pin 88 meshes with the pinion 82 so that thehandle 86 cannot move until the safety pin 88 is retracted. In preferredembodiments, the safety pin 88 is provided on one side of the frame 26and the handle 86 is provided on an opposite side of the frame 26. Thisparticular design feature ensures that an operator's hands will not bepositioned under the cutting blade 32 during a cutting operation becauseone of the operator's hands must retract the safety pin 88 while theother hand is pulling the handle 86. Once the safety pin 88 has beenretracted, the handle 86 is preferably pulled downward towards theoperator so as to rotate the pinion 82.

Referring to FIGS. 5A-5C, the cutting blade 32 is relatively massive andhas a cutting edge 90 which faces the window shade to be cut. In certainembodiments the cutting blade 32 includes carbide steel. In otherpreferred embodiments the cutting edge 90 of the cutting blade 32 mayinclude diamond. As shown in FIGS. 5B and 5C, the cutting blade 32includes a first face 92 which is substantially flat. The cutting blade32 also has a second face 94 remote from the first face 92. The secondface 94 includes a concave pocket 96 cut into the second face 94. Thethickness of the pocketed portion 96 of the cutting blade 32 issubstantially thinner than the remaining portion of the blade whichsurrounds the pocketed portion. For example, as shown in FIG. 5B, upperportion 98 of the cutting blade 32, i.e. the massive portion surroundingthe pocket 96, is between approximately 0.40 to 0.50 inches thick whilethe pocketed portion 96 of the blade 32 is between approximately 0.10and 0.20 thick. The pocket 96 preferably includes a tapered sectionwhich tapers outwardly from the cutting edge 90 of the blade 32. Inother words, the pocket 96 of the blade 32 becomes thicker as thedistance from the cutting edge 90 increases. However, the thickness ofthe pocket 96 always remains less than the thickness of the massiveportion 98 of the blade 32. The massive portion 98 of the cutting blade32 stabilizes the blade 32 and prevents the cutting edge 90 from flexingand bowing during a cutting operation which could result in an erraticcut line which is not vertical. The pocketed portion 96 is preferablythe only portion of the blade 32 which engages the end portion of theshade 36 being cut. Thus, the pocketed portion 96 enables the blade 32to effectively slice through the window shade 36 because the pocketedportion 96 is relatively thin.

Referring to FIG. 5D, pocketed portion 96 preferably includes a taperedregion having a first tapered section 100 or bevel which extends up andaway from the cutting edge 90 of the blade 32. The beveled section 100and the first face 92 of the cutting blade 32 form a first acute angledesignated A₁. The pocket 96 also includes a second tapered section 104which extends up and away from the beveled section 100. The secondtapered section 104 and the first face 92 of the cutting blade 32 form asecond acute angle designated A₂ which is smaller than the first acuteangle designated A₁.

Referring to FIGS. 1 and 2A, the cutting apparatus 20 also preferablyincludes a measuring assembly generally designated as 108 for measuringthe end portion of the window shade being cut. In certain preferredembodiments, the measuring assembly includes a guard, hereinafterreferred to as right hand guard 110, which prevents an operator fromplacing his or her hands under the cutting blade 32. The right handguard 110 includes a removable end plate 112 remote from the cuttingblade 32 which provides access to an area of the cutting apparatus 20immediately downstream from the cutting blade 32. The right hand guard110 preferably includes a rugged, but clear material which enables anoperator to observe the cutting operation, such as Lexan, Plexiglas orAcrylic. The measuring assembly 108 includes a measuring instrument 114,such as a ruler, which is permanently attached to the right hand guard110 for measuring the end portion of the window shade being cut. Theruler 114 is preferably attached to the underside of the right handguard 110 and is visible through the right hand guard 110. The guard 110includes two sots 116A and 116B on opposite sides thereof which extendhorizontally away from the cutting blade 32. A stop block 118 isslidably mounted in the slots 116A and 116B and is movable toward andaway from the cutting blade 32. The stop block 118 includes a stop knob120 at one side thereof which can be hand tightened to secure the stopblock 118 in place within the slots 116A and 116B. The stop block 118preferably underlies the ruler 114 so that the length of the end portionof the window shade being cut can be accurately measured by aligning thestop block 118 with a certain spot on the ruler. For example, if acustomer requests that two inches be cut off from one end of the windowshade, then the stop block 118 is moved to a position two inches awayfrom the cutting blade 32, as indicated by the ruler 114. Once the stopblock 118 has been positioned at the desired distance from the cuttingblade 32, the stop knob 120 is hand-tightened to secure the stop block118 in place.

The stop block 118, and preferably the entire measuring assembly 108, isconnected to a cam follower 122. In turn, the cam follower 122 isinterconnected with the pinion 82 so that the entire measuring assembly108 including the stop block 118 cams away from the cutting blade 32 asthe cutting blade slices through an end portion of the window shade.Because the stop block 118 cams away, the end of the window shade 36being cut is able to freely pivot down and away from the cutting blade32, thereby reducing the compression force exerted by the blade 32 uponthe window shade. In certain preferred embodiments, a cam collar 124 isconnected to the pinion 82 for rotating with the pinion. The cam collar124 has a groove 126 formed on the outer periphery thereof. The camfollower 122 is positioned within the groove 126 for interconnecting thecam collar 124 and the measuring assembly 108. When the pinion 82rotates, the cam follower 122 moves through the groove 126 in the camcollar 124. The groove 126 guides the cam follower 122 away from thecutting blade 32 which causes the measuring assembly 108 and the stopblock 118 to cam away from the cutting blade 32.

As mention above, the cutting apparatus 20 according to the presentinvention will preferably be located in a retail store so that customersmay have window shades efficiently and economically cut to specifiedlengths. The cutting apparatus 20 will preferably be provided over asupporting element, such as a table. The cutting apparatus 20 willpreferably be bolted or firmly secured to the table. The table may havean opening adjacent and/or downstream from the cutting blade 32 so thecut end portion of the window shade 36 can fall through the opening andinto a waste container. Typically, a customer desiring window shades cutto a specified length will provide a salesperson (hereinafter referredto as the “operator”) with the dimensions of one or more windowopenings. The operator may then refer to a chart, typically provided bythe manufacturer of the window shades, in order to select a particularpre-stocked shade to be cut. Preferably the manufacturer will provideanywhere from five to ten, or even more, different models of shades. Themanufacturer's chart may also provide the operator with informationconcerning how many inches or feet must be cut off one or both ends ofthe window shade.

Referring to FIGS. 6A and 6B, the end 128 of the window shade 36 to becut is preferably positioned at the first end 52 of the cutting surface24 of the base 22. After the end caps 44 (not shown) have been removedfrom the head rail 38 and the base rail 40, the window shade 36 ispreferably aligned over the top surface 24 so the head rail 38 faces theguide rail 58 or mandrel and the base rail 40 faces the clamp block 60.The “C”-shaped opening 42 at the top of the head rail 38 is aligned withand slid over the mandrel 58, whereupon the head rail 38 is deemed to becaptured by the mandrel. Once the head rail 38 has been captured by themandrel 58, the window shade 36 is moved or inserted toward the secondend 54 of the cutting surface 24 and the stop block 118. The windowshade 36 continues to be inserted into the cutting apparatus 20 untilthe end portion 128 of the window shade 36 abuts against the stop block118. At this stage, the cutting blade 32 overlies the end portion 128 ofthe window shade 36.

After the window shade 36 has been fully inserted into the cuttingapparatus 20 and abutted against the stop block 118, the operator firmlysecures the window shade 36 in place over the top surface 24 using theclamping assembly. The operator rotates the crank handle 74, preferablyin a clockwise direction, which rotates the shaft, which in-turn causesthe clamp block 60 to move toward the window shade 36 and the mandrel58. The operator continues to hand-tighten the crank handle 74 until theclamp block 60 abuts against the base rail 40 and compresses the windowshade 36 between the clamp block 60 and the mandrel 58. Once the windowshade 36 has been secured over the cutting surface 24 of the base 22,the operator may cut the end 128 of the window shade 36.

Referring to FIGS. 2A and 2B, before the handle 86 may be pulled to cutthe window shade 36, the safety pin 88 in the frame 26 must be retractedso as to free the pinion 82 for rotation. As the safety pin 88 ismaintained in the retracted position, the handle 86 is preferablyrotated downward toward the operator which rotates the pinion 82. As thepinion 82 rotates, the teeth 84 of the pinion 82 mesh with the teeth 80of the rack 78 to move the cutting assembly 30 downward within theangled guide tracks 28A and 28B. As the cutting assembly 30 movesdownward, the cutting blade 32 moves along the movement axis designatedA—A in a direction which is diagonal to the top cutting surface 24 ofthe base 22 and the window shade 36. In other words, the cutting blademoves in a direction which has both vertical (y-axis) and horizontal(x-axis) components. Because the cutting blade 32 moves diagonally withrespect to both the cutting surface 24 of the base 22 and the windowshade 36 secured thereto, the cutting blade 32 slices through the windowshade 36 in a diagonal direction. This slicing action, as opposed to anentirely vertical cut (Y-axis) or chopping action, greatly reduces thecompression forces exerted by the blade 32 upon the window shade 36 andresults in the formation of a cleaner cut. The slicing action alsoprevents the cut edges of the head and bottom rails 38, 40 from breakingor cracking.

Referring to FIG. 6B, the window shade is preferably configured over thetop surface 24 of the base 22 so that the cutting edge 90 simultaneouslyabuts against the bottom rail 40, the head rail 38 and the windowcovering material 41. As the cutting edge 90 slices through the windowshade 36 in a diagonal direction, the mandrel 58 supports the head rail38 and functions as an inner die. Because the mandrel extends all theway to the second end 54 of the cutting surface 24 of the base 22 andterminates immediately before the first face 92 of the cutting blade 32,an extremely clean cut can be formed at the end of the head rail 38. Themandrel 58 also prevents the head rail 38 from rotating in the movementdirection of the cutting blade 32 while it is being cut, thereby furthercontributing to the formation of a straight and clean cut.

FIGS. 7A-7C show the cutting blade 32 described above as the bladeslices through the window shade 36. The window shade 36 and the base 22are depicted as blocks for clarity of illustration. Initially, thecutting edge 90 engages the entire top of the window shade 36. In otherwords, the cutting edge 90 simultaneously engages the base rail, thewindow covering material and the head rail. As shown in FIG. 7B, thecutting edge moves vertically downward along the y-axis and to the sidealong the x-axis, i.e. diagonally through the window shade 36. Thecutting edge 90 continues to move diagonally through the window shade 36until the blade 32 has sliced completely through the shade 36, as shownin FIG. 7C. During the entire cutting operation only the pocket 96engages the shade 36 which further minimizes the forces the blade exertsupon the shade 36. Moreover, the cutting edge 90 of cutting blade 30 toremain substantially parallel to cutting surface 24 during the entirecutting operation.

FIGS. 8A and 8B show side views of FIGS. 7A and 7C, respectively. Whenthe blade 32 initially engages the window shade 36, the stop block 118abuts against the end of the window shade 36. However, shortly after theblade 32 begins to slice through the window shade 36, the stop block 118cams away from the cutting blade 36 which allows the end portion 128 ofthe window shade 36, which is preferably unsupported, to freely pivotaway from the cutting blade 32. By enabling the cut end portion 128 topivot away from the blade 32, the forces exerted upon the window shade36 by the cutting blade 32 are greatly reduced. This is of particularimportance toward the end on the cutting stroke when the blade 32 hasalmost completely cut through the window shade 36 because at this pointthere exists an increased likelihood that the blade 36 will compress thehead rail 38 and the bottom rail 40 which greatly increases thelikelihood that those elements will crack.

As shown in FIGS. 8A and 8B, because the first face 92 of the cuttingblade 32 is vertical and/or substantially flat, the blade 36 providesthe window shade 36 with a clean, squared-off cut. As mentioned above,the pocketed portion 96 of the blade 32, which is much thinner than therest of the blade 36, is the only portion of the blade which engages thewindow shade. This preferred design minimizes the thickness of thecutting blade 32 actually cutting through the window shade 36, therebypreventing the head rail 38 and the bottom rail 40 from cracking,breaking or tearing as the window shade 36 is cut. Because the pocketedportion 96 is tapered, the end portion 128 of the window shade being cutpivots away from the blade 32. When the blade 32 reaches the bottomportion of the cut, the thickness of the blade 32 at that section isparticularly thin so that the blade 32 does not crack or break the headrail 38 or the bottom rail 40. The pocketed design results in only athin portion of the blade 30 contacting the window shade 36; however,the massive portion of the blade 32 surrounding the pocket 96 stabilizesthe pocketed portion 96 and prevents the blade 32 from bending during acutting operation.

After the end portion 128 of the window shade 36 has been completelycut, the end portion 128 falls down and away from the cutting apparatus20 and preferably through an opening in the supporting table. Theoperating handle 86 may then be rotated upward to its initial startposition which will move the cutting blade 32 away from the backup 76.As the handle 86 is rotated upward, the safety pin 88 will re-engage thepinion 82 to lock the pinion 82 in place and prevent further rotation ofthe pinion. The crank handle 74 is then preferably rotated in acounter-clockwise direction to release the clamping force on the windowshade 36 so that the window shade 36 may be removed from the cuttingapparatus 20. The window shade 36 may then be removed by sliding thewindow shade 36 away from the first end 52 of the cutting surface 24 ofthe base 22, so that the “C”-shaped opening 42 in the head rail 38 maybe released from the mandrel 58. If necessary, a second end of thewindow shade 36 may also be cut to a specified length usingsubstantially the same techniques as described above. After the cuttingoperation is complete, the end caps 44 are preferably re-installed atthe ends of the head rail 38 and the base rail 40.

As will be appreciated, numerous variations and combinations of thefeatures discussed above may be utilized without departing from thepresent invention as defined in the claims. For example, the cuttingassembly may follow an eccentric motion over a certain area of travel soas to multiply the force exerted by the cutting blade. In otherembodiments, the cutting assembly may include a laser for cutting thewindow shade with laser light energy. Accordingly, the foregoingdescription of the preferred embodiments should be taken by way ofillustration rather than by way of limitation of the present invention.

1. An apparatus for cutting a window covering including a head rail, abottom rail and slats window covering material extending between thehead rail and the bottom rail, said apparatus comprising: a base havinga substantially flat cutting surface; a frame overlying said cuttingsurface and mounted to said base, said frame and said cutting surfacedefining a receiving area therebetween for receiving said windowcovering; said base including a clamping assembly slidably movable in ahorizontal direction parallel to said cutting surface for securing thebottom rail, the slats window covering material and the top rail of saidwindow covering in a side-by-side arrangement atop said cutting surfaceso that the bottom rail, the slats window covering material and the toprail are in contact with the substantially flat cutting surface; acutting assembly including a cutting blade having a cutting edge mountedto said frame for sliding along a movement axis toward and away fromsaid receiving area, said movement axis having a first component ofmovement extending in a direction substantially parallel to said cuttingsurface and a second component of movement extending in a directionsubstantially perpendicular to said cutting surface; and a driverconnected with said cutting assembly for imparting sliding motion tosaid cutting assembly for moving said cutting blade along the movementaxis toward said receiving area, wherein said cutting surface, saidclamping assembly and said cutting assembly are arranged so that thecutting edge of said cutting blade simultaneously engages and cutsthrough the bottom rail, the slats window covering material and the headrail of said window covering.
 2. The apparatus as claimed in claim 1,wherein the cutting edge of said cutting blade remains substantiallyparallel to said substantially flat cutting surface when engaging andcutting through the bottom rail, the slats window covering material andthe head rail of said window covering.
 3. The apparatus as claimed inclaim 1, wherein said cutting edge of said cutting blade remainssubstantially parallel to said substantially flat cutting surface duringmovement along the movement axis.
 4. The apparatus as claimed in claim1, wherein said substantially flat cutting surface includes a first endand a second end opposite the first end, the second end of said cuttingsurface including a backup opposing the cutting edge of said cuttingblade, and wherein said backup is adapted, to engage the cutting edgeafter the cutting edge passes through the bottom rail, the slats windowcovering material and the head rail of said window covering forminimizing dulling of the cutting edge.
 5. The apparatus as claimed inclaim 4, wherein said backup is made of nylon.
 6. The apparatus asclaimed in claim 4, said base further comprising a guide mandrelextending between the first and second ends of said cutting surface,wherein said guide mandrel is adapted to slide within an opening of saidtop rail for guiding movement of said window covering across saidcutting surface.
 7. The apparatus as claimed in claim 6, wherein saidclamping assembly is movable across said substantially flat cuttingsurface toward said guide mandrel for compressing the bottom rail, theslats window covering material and the top rail between said clampingassembly and said guide mandrel.
 8. The apparatus as claimed in claim 7,wherein said clamping assembly includes a clamping block engagable withthe bottom rail of said window covering for urging the bottom railtoward the top rail so as to compress the slats window covering materialbetween the bottom rail and the top rail.
 9. The apparatus as claimed inclaim 1, wherein said cutting blade includes a pocketed portion that isthinner than a massive portion of said cutting blade that surrounds thepocketed portion, and wherein the cutting edge of said cutting blade isconfined entirely with the pocketed portion of said cutting blade. 10.The apparatus as claimed in claim 9, wherein only the pocketed portionof said cutting blade engages the bottom rail, the slats window coveringmaterial and the top rail of said window covering during a cuttingoperation.
 11. The apparatus as claimed in claim 1, further comprising ameasuring assembly adjacent the second end of said cutting surface formeasuring an end portion of said window covering to be cut during acutting operation, wherein said measuring assembly includes a stop blockabutable against the end of said window covering being cut and linkedwith said driver for moving away from said window covering during acutting operation.
 12. An apparatus for cutting a window coveringincluding a head rail, a bottom rail and slats window covering materialextending between the head rail and the bottom rail, said apparatuscomprising: a base having a substantially flat cutting surface; a frameoverlying said cutting surface and mounted to said base; said baseincluding a clamping assembly slidably movable in a horizontal directionparallel to said cutting surface for securing the bottom rail, the slatswindow covering material and the top rail of said window covering in aside-by-side arrangement atop said cutting surface so that the bottomrail, the slats window covering material and the top rail are in contactwith the substantially flat cutting surface; a cutting assemblyincluding a cutting blade having a cutting edge mounted to said framefor sliding along a movement axis toward and away from said cuttingsurface, said movement axis having a first component of movementextending in a direction substantially parallel to said cutting surfaceand a second component of movement extending in a directionsubstantially perpendicular to said cutting surface; and a driverconnected with said cutting assembly for moving said cutting blade alongthe movement axis toward said cutting surface, wherein said cuttingsurface, said clamping assembly and said cutting assembly are arrangedso that the cutting edge of said cutting blade simultaneously engagesand cuts through the bottom rail, the slats window covering material andthe head rail of said window covering, and wherein the cutting edge ofsaid cutting blade remains substantially parallel to said substantiallyflat cutting surface when engaging and cutting through the bottom rail,the slats window covering material and the head rail of said windowcovering.
 13. The apparatus as claimed in claim 12, wherein saidsubstantially flat cutting surface includes a first end and a second endopposite the first end, the second end of said cutting surface includinga backup opposing the cutting edge of said cutting blade, and whereinsaid backup is adapted to engage the cutting edge after the cutting edgepasses through the bottom rail, the slats window covering material andthe head rail of said window covering for minimizing dulling of thecutting edge.
 14. The apparatus as claimed in claim 12, said basefurther comprising a guide mandrel extending between first and secondends of said cutting surface, wherein said guide mandrel is adapted toengage said top rail for guiding movement of said window covering acrosssaid cutting surface.
 15. The apparatus as claimed in claim 14, whereinsaid clamping assembly is movable across said substantially flat cuttingsurface and toward said guide mandrel for compressing the bottom rail,the slats window covering material and the top rail between saidclamping assembly and said guide mandrel.
 16. The apparatus as claimedin claim 12, wherein said cutting blade includes a pocketed portion thatis thinner than a massive portion of said cutting blade, the massiveportion of said cutting blade surrounding the pocketed portion, andwherein the cutting edge of said cutting blade is confined entirely withthe pocketed portion of said cutting blade.
 17. The apparatus as claimedin claim 16, wherein only the pocketed portion of said cutting bladeengages the bottom rail, the slats window covering material and the toprail of said window covering during a cutting operation.